US9630346B2

Movatterモバイル変換

Info

Publication number: US9630346B2
Application number: US13/785,563
Authority: US
Inventors: Lih-Sheng Turng; Xiaofei Sun
Original assignee: Wisconsin Alumni Research Foundation
Current assignee: Wisconsin Alumni Research Foundation
Priority date: 2013-03-05
Filing date: 2013-03-05
Publication date: 2017-04-25
Also published as: US20140252669A1

Abstract

A method of fabricating an injection-molded component is provided. The method includes the step of introducing pellets into an injection barrel of an injection molding machine. The pellets include a first supercritical fluid. The pellets are plasticized in the injection barrel and a second supercritical fluid is injected into the plasticized pellets. The second supercritical fluid and the plasticized pellets are mixed to form a mixed material. The mixed material is injected into a mold.

Description

FIELD OF THE INVENTION

This invention relates generally to injection molding, and in particular, to a method for fabricating a foamed injection molded component with better surface quality and lower weight than prior components.

BACKGROUND AND SUMMARY OF THE INVENTION

Methods for processing plastic, especially thermoplastics, to make personal and consumer items and packaging typically utilize one or more polymers and employ techniques such as injection molding, blow molding, extrusion, and thermoforming. Microcellular techniques are employed to disperse gases in the polymer, thereby resulting in the polymer being “foamed.” The “foamed” polymer includes a preset amount of dissolved gas that, when heated and processed, emerges from the plastic item or packaging in the form of bubbles or voids.

Microcellular injection molding is an emerging special injection molding process capable of producing foamed parts with many advantages. During the microcellular injection molding process, a supercritical fluid is introduced into a molten polymer prior to the polymer being injected into a mold. The polymer solidifies in the mold to form a desired component. The introduction of the supercritical fluid prior to injection of the polymer into the mold causes tiny bubbles to be distributed throughout the molded component. By providing tiny bubbles in the molded component, the amount of material necessary to mold the component is reduced, while the dimensional stability of the molded component is improved. Hence, this microcellular injection molding process allows for the production of lightweight and dimensionally stable plastic components with complex geometries while reducing the amount of raw material.

While the microcellular injection molding process saves on material cost and improves production efficiency as compared to conventional solid injection molding, the process does have certain limitations. By way of example, microcellular injection molding requires specially designed supercritical fluid delivery and dosing systems to be installed on the injection molding machine for the delivery of the supercritical fluid as a physical blowing agent. In addition, modifications need to be made to the injection molding machine itself, including the installation of a supercritical fluid delivery device and a special injection screw with mixing elements for effectively mixing the supercritical fluid with the liquid polymer. These two factors lead to an increase in capital investment, especially when a large number of injection molding machines need to be modified.

Alternatively, other methodologies may be used to produce foamed molded parts. By way of example, chemical blowing agents can be used to produce foamed injection molded parts without the need of installing any additional equipment on the injection molding machine. However, residuals tend to appear in the parts after the reaction, which leads to the degradation of the polymer matrix and to possible contamination of the mold. Furthermore, the use of chemical blowing agents does not allow for good control over the foaming process or the cellular foam structure of the parts. In addition, chemical blowing agents are not suitable for processing high temperature polymers due to its early decomposition.

A still further way to produce, foamed injection molded parts using a conventional injection molding machine is to saturate pellets of a polymer with a physical blowing agent in a high pressure vessel prior to introduction of the polymer into the injection molding machine. While parts with a cellular foam structure can be manufactured utilizing this methodology, the production rate of pre-saturated pellets using a high pressure vessel is usually not high enough for continuous mass production of injection molded parts.

Therefore, it is a primary object and feature of the present invention to provide a method for fabricating foamed, injection molded components in a cost-effective way while ensuring a satisfactory production rate.

It is a further object and feature of the present invention to provide a method for fabricating foamed injection molded components which produces components having smaller cell size and increased cell density over components produced by current methods.

It is a still further object and feature of the present invention to provide a method for fabricating foamed, injection molded components which produces lightweight components with comparable properties as those produced by current methods, but at a lower cost.

It is a still further object and feature of the present invention to provide a method for fabricating foamed, injection molded components which is simple and which may be performed with standard injection molding machinery.

In accordance with the present invention, a method of fabricating an injection-molded component is provided. The method includes the step of introducing pellets including a first supercritical fluid and polymeric material into an injection barrel of an injection molding machine. The pellets are plasticized within the injection barrel and a second supercritical fluid is introduced into the plasticized pellets to form an injection material. The injection material is injected into a mold.

The method may include the additional steps of providing a polymeric material. The polymeric material is heated and the first supercritical fluid is introduced to produce a melt. The melt is extruded and cooled rapidly to solid strands. The strands are then pelletized. The extruded melt is unfoamed. It is contemplated for the first supercritical fluid to be nitrogen and for the second supercritical fluid to be carbon dioxide. The injection material may be mixed prior to injecting the injection material into the mold. The injection molding machine includes a hopper communicating with the injection barrel. The pellets are introduced into the hopper prior to introduction of the pellets into the injection barrel.

In accordance with a further aspect of the present invention, a method of fabricating an injection-molded component is provided. The method includes the steps of providing a polymeric material and introducing a first supercritical fluid into the polymeric material. Pellets are formed from the polymeric material and the first supercritical fluid. The pellets are introduced into an injection barrel of an injection molding machine and the pellets are plasticized. A second supercritical fluid is introduced into the plasticized pellets to form an injection material. The injection material is injected into a mold.

The step of forming pellets from the polymeric material and the first supercritical fluid may include the additional steps of heating the polymeric material and introducing the first supercritical fluid to produce a melt. The melt is extruded and the cooled rapidly to form solid strands. The strands are introduced into a pelletizer. The extruded melt is unfoamed. It is contemplated for the first supercritical fluid to be nitrogen and the second supercritical fluid to be carbon dioxide.

The supercritical fluid is mixed into the plasticized material prior to injecting the injection material into the mold. The injection molding machine includes a hopper communicating with the injection barrel. The pellets are introduced into the hopper prior to introduction of the pellets into the injection barrel.

In accordance with a still further aspect of the present invention, a method of fabricating an injection-molded component is provided. The method includes the step of introducing pellets into an injection barrel of an injection molding machine. The pellets include a first supercritical fluid. The pellets are plasticized in the injection barrel and a second supercritical fluid and the plasticized pellets are mixed to form a mixed material. The mixed material is injected into a mold.

The pellets are formed from a polymeric material and the first supercritical fluid. The step of forming pellets from the polymeric material and the first supercritical fluid includes the steps of heating the polymeric material and introducing the first supercritical fluid to produce a melt. The melt is extruded and cooled to form solid strands. The strands are introduced into a pelletizer. The extruded melt is unfoamed. The first supercritical fluid may be nitrogen and the second supercritical fluid may be carbon dioxide. The injection molding machine includes a hopper communicating with the injection barrel. The pellets are introduced into the hopper prior to introduction of the pellets into the injection barrel.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings furnished herewith illustrate a preferred construction of the present invention in which the above advantages and features are clearly disclosed as well as others which will be readily understood from the following description of the illustrated embodiment.

In the drawings:

FIG. 1 is a schematic view of an injection molding machine for use in performing the methodology of the present invention; and

FIG. 2 is a representation of the morphology of components fabricated in accordance with the methodology of the present invention.

DETAILED DESCRIPTION OF DRAWINGS

Referring toFIG. 1, an apparatus for performing the methodology of the present invention is generally designated by thereference numeral10.Apparatus10 includes equipment set-up12 for the production of supercritical fluid (SCF)-laden pellets. Set-up12 includesextruder14 havingscrew16 extending along a longitudinal axis and being rotatably supported withinbarrel18 to convey polymeric material downstream withinpolymer processing space20 toward extrusion die22. Seals (not shown) may be provided on the flights ofscrew16, for reasons hereinafter described.Barrel18 is adapted to receive polymeric materials that are fluidic, or can form a fluid that subsequently hardens to form a conventional, or solid, polymeric article or component.Barrel18 includes a first end fluidly connected to mold extrusion die22 throughnozzle24 and a second, oppositeend having aperture26 extending therethrough. Drivemotor28 is operatively connected to screw16 bydrive shaft30 extending throughaperture26 in second end ofbarrel18. Drivemotor28 is operatively connected to a controller (not shown) for controlling rotational and axial movement ofscrew16.

Extruder

14 further includeshopper32 for introducing a polymer material intobarrel18. The material inhopper32 is delivered intopolymer processing space20 withinbarrel18 through anorifice34.Polymer processing space20 is defined by the outer surface ofscrew16 and the inner surface ofbarrel18. It is noted that the polymer material may be in the form of solid pellets introduced throughorifice34 and plasticized withinbarrel18. In connection with the present invention, it is noted a fluidic stream of polymeric material is established in thebarrel18.

A plurality oftemperature control units36 are positioned alongbarrel18. For example,control units36 can take any suitable form such as electrical heaters or the like. It is intended forcontrol units36 to heat a stream of pelletized or fluid polymeric material withinbarrel18 to facilitate melting and/or cooling of the stream to control viscosity. If desired,control units36 can operate differently at different locations alongbarrel18.

Extruder

14 further includes at least oneport40 fluidly connectingsyringe pump42 topolymer processing space20 withinbarrel18. As hereinafter described, it is intended for a supercritical fluid to be injected into the polymeric material within thepolymer processing space18 to form a SCF-laden polymeric material therein. A pressure and metering device orinjector44 is provided betweensyringe pump42 and the at least oneport40. In the preferred embodiment,injector44 is configured as two cylinders, a smaller one with a tip on top of a larger diameter one. In this injector design, the tip has been removed, and it has a broad area, to allow more gas to penetrate through the Porcerax, which is a porous metallic alloy that allows the supercritical fluid to flow therethrough, while preventing the much more viscous polymer melt from leaking therein. As such,injector44 may be used to meter the supercritical fluid introduced into the polymeric stream withinbarrel18.

It is intend forsyringe pump42 to facilitate the flow of a blowing agent, namely, a liquid or supercritical fluid, (e.g. nitrogen or carbon dioxide) fromsource43 toinjector44 at the low, constant flow rate. Oneexemplary syringe pump42 is available as Model No. 260D from Teledyne ISCO of Lincoln, Nebr.Pressure regulator46 and a pump controller (not shown) interconnectssyringe pump42 andinjector44 and controls the flow rate of the supercritical fluid provided thereto. In instances in which the supercritical fluid is carbon dioxide,chiller70

interconnects source

43 andsyringe pump42. As the carbon dioxide flows fromsource43 tosyringe pump42,chiller70 acts to maintain the carbon dioxide in a liquid state under pressure, thereby facilitating the control over the flow rate and the pressure of the carbon dioxide supplied toinjector44. In instances in which the supercritical fluid is nitrogen,chiller70 is unnecessary since control of the flow and pressure of thereof can be attained at or near ambient or room temperature.

In operation, it is contemplated to provide a polymeric material, e.g., polycarbonate, polystyrene, polypropylene or low-density polyethylene, in a pelletized form inhopper32. At the beginning of a cycle, screw16 is axially positioned adjacent the first end ofbarrel18 in an initial position. The pelletized polymeric material inhopper32 is delivered intopolymer processing space20 inbarrel18 throughorifice34.Screw16 is rotated to urge the polymeric material downstream such that the mechanical energy generated by rotation ofscrew16 andcontrol units36 plasticize the polymeric material inpolymer processing space20 inbarrel18. The first supercritical fluid is introduced intopolymer processing space20 throughport40 where it is mixed with the polymeric material viascrew16.Screw16 maintains sufficient back pressure at all times to prevent premature foaming or the loss of pressure withinextruder14 which would allow the single phase solution to return to a two phase solution.

The seals located on the flights ofscrew16 limit the escape of any supercritical fluid flashing off the plasticized polymeric material. In embodiments wherein LDPE (or similar thermoplastics) is used as the polymeric material, however, the solubility of the supercritical fluid increases with increasing melt temperatures. Hence, as the plasticizing of the polymeric material occurs, the supercritical fluid will likely remain in the LDPE. In other words, as long as the gas content is maintained below the saturation or super saturation point, the supercritical fluid does not escape frombarrel18.

Extrusion die22 is configured such that the SCF-laden polymeric material will not foam or foam minimally before and after it exits nozzle ofextruder14. More specifically, extrusion die22 is of sufficient length to facilitate the cooling of the SCF-laden polymeric material, thus suppressing the nucleation of bubbles therein. Also, to prevent the foaming from taking place prematurely, the temperature can be reduced further by cooling the SCF-laden polymeric material with vortex gas cooling tubes and/or extruding the SCF-laden polymeric material into a water bath. In the course of the operation of the equipment of the proposed set-up12, the amount of supercritical fluid that can be added without premature foaming of the SCF-laden polymeric material can be determined experimentally. Other variables that ensure process stability, determine foaming rates, assess the shelf life of the SCF-laden pellets produced, and contribute to subsequent extrusion and injection molding processes can also be determined.

The SCF-laden polymeric material exits extrusion die22 in strand form and cooled, e.g. by means of a water bath or, in the case of a water soluble polymeric material, vortex gas cooling tubes or an air blade. Thereafter, the strands of SCF-laden polymeric material are fed topelletizer74, wherein the strands are chopped or otherwise cut into suitablysized pellets72.Pellets72 are oven dried to remove the moisture content thereof. Once produced,pellets72 are used by an injection molding machine to produce a desired component, as hereinafter described.

In order to form the component in accordance with the methodology of the present invention,apparatus10 further includes an injection molding machine, generally designated by thereference numeral80.Injection molding machine80 includesextruder82 fluidly connected to mold84.Screw86 extends along a longitudinal axis and is rotatably supported withinbarrel88 to convey polymeric material downstream withinpolymer processing space90 towardmold84.Barrel88 is adapted to receive polymeric materials that are fluidic, or can form a fluid that subsequently hardens to form a conventional, or solid, polymeric article.Barrel88 includes a first end fluidly connected to mold84 through nucleatingpathway92 ofnucleator94 and a second, oppositeend having aperture96 extending therethrough. Drivemotor98 is operatively connected to screw86 bydrive shaft100 extending throughaperture96 in second end ofbarrel88. Drivemotor98 is operatively connected to a controller (not shown) for controlling rotational and axial movement ofscrew86.

Injection molding machine

80 includeshopper100 for receivingpellets72 of the pelletized SCF-laden polymeric material therein.Pellets72 are delivered intopolymer processing space90 withinbarrel88 throughorifice102.Polymer processing space90 is defined by the outer surface ofscrew86 and the inner surface ofbarrel88.Injection molding machine80 further includes at least onefoaming agent port104 fluidly connectingfoaming agent source106 topolymer processing space90 withinbarrel88. As hereinafter described, it is intended for a foaming agent to be injected into the plasticized polymeric material within thepolymer processing space88 to form a polymer and foaming agent solution therein. Pressure andmetering device108 is provided betweenfoaming agent source106 and the at least onefoaming agent port104. Pressure andmetering device108 may be used to meter the foaming agent so as to control the amount of the foaming agent in the polymeric stream withinbarrel88 and maintain the foaming agent at a desired level.

Although foamingagent port104 may be located at any of a variety of locations alongbarrel88, it is preferably located just upstream from mixingsection110 ofscrew86 and from foamingagent receiving section112 ofscrew86 whereinscrew86 includes unbroken flights. Mixingsection110 is adapted for mixing the foaming agent and SCF-laden polymeric material to promote the formation of a single-phase solution of the SCF-laden polymeric material and the foaming agent withinbarrel88.

A plurality oftemperature control units120 are positioned alongbarrel88. For example,control units120 can take any suitable form such as electrical heaters or the like. It is intended forcontrol units120 to heat a stream of pelletized or fluid polymeric material withinbarrel88 to facilitate melting and/or cooling of the stream to control viscosity and, in some cases, the solubility of the foaming agent.Control units120 can operate differently at different locations alongbarrel88. For example, a first portion ofcontrol units120 may heat the stream at one or more locations alongbarrel88, while a second portion of thecontrol units120 may cool the stream at one or more different locations alongbarrel88.

A restriction element (not shown) may be provided upstream of foamingagent port104 to maintain the SCF-laden polymeric material and foaming agent solution downstream of the restriction element at sufficient pressure throughout the injection process. The restriction element can take any of a variety of forms known in the art for restricting the upstream flow of polymer material, such as a blister, a dam across the feed-section of the screw, a reverse screw flight, a valve or a ring check valve.

In order to form a desired component,pellets72 are deposited inhopper100. A foaming agent in the form of a supercritical fluid, e.g., carbon dioxide or nitrogen, is provided by foamingagent source106 to theinjection molding machine80. It is noted that other foaming agents may be used without deviating from the scope of the present invention. At the beginning of an injection cycle, screw86 is axially positioned adjacent the first end ofbarrel88 in an initial position. The pelletized SCF-laden polymeric material inhopper100 is delivered intopolymer processing space90 inbarrel88 throughorifice102 and screw86 is rotated to urge the SCF-laden polymeric material downstream. Supercritical gas, e.g. carbon dioxide or nitrogen, is introduced intopolymer processing space90 through at least onefoaming agent port104 where it is mixed with the SCF-laden polymeric material viascrew86.Screw86 maintains sufficient back pressure at all times to prevent premature foaming or the loss of pressure withinextruder82 which would allow the single phase solution to return to a two phase solution. The single-phase solution of the second supercritical fluid and the SCF-laden polymeric material formed inextruder82 has a very low viscosity which advantageously allows lower temperature molding, as well as, rapid filling of molds having close tolerances to form very thin molded parts. The polymeric material and foaming agent is accumulated inaccumulation region130 withinbarrel88 downstream ofscrew86.

Once a sufficient volume of the solution has accumulated in theaccumulation region130, screw86 is moved in a downstream direction so as to inject the solution into nucleatingpathway92 throughinlet128 thereof. As the single-phase solution of the SCF-laden polymeric material and foaming agent passes through nucleatingpathway92, the pressure drop in the nucleatingpathway92 causes the nucleation of the solution. The nucleated SCF-laden polymeric material is injected into the molding chamber ofmold84 throughoutlet132 of nucleatingpathway92. After injection, screw86 once again rotates to build up the polymeric material (and foaming agent) in theaccumulation region130 for the next injection.

The nucleated SCF-laden polymeric material received in the molding chamber ofmold84 begins to cool as soon as the nucleated SCF-laden polymeric material contactsinner surface84aofmold84. The molding chamber ofmold84 is filled with the nucleated SCF-laden polymeric material and the nucleated SCF-laden polymeric material solidifies into a part as it cools. After a sufficient time period has passed, the cooled part may now be ejected frommold84. As is conventional, the size and shape of the part corresponds to the size and shape of the molding chamber ofmold84.Mold84 is opened and the part is ejected therefrom. Once the part is ejected,mold84 is closed and the process may be repeated.

As described, the methodology of the present inventions allows for the introduction of two, highly controlled gases, in their supercritical states to create micron-sized voids in thin wall molded parts. The voids are created or nucleated as a result of homogeneous nucleation (or heterogeneous nucleation if fillers are present in the polymeric material) that occurs when a single-phase solution of the SCF-laden polymeric material and the supercritical fluid introduced intoinjection molding machine80 pass through nucleatingpathway92. The fabrication ofpellets72 from the SCF-laden polymeric material and the introduction of a second supercritical fluid in the molding of a desired component yield a remarkable improvement in foam morphology. More specifically, the methodology of the present invention allow for the use of both nitrogen and carbon dioxide in the foaming process, thereby enabling the processing benefits and material characteristics of both blowing agents and yielding a component having features superior to a component fabricated using either nitrogen or carbon dioxide alone.

In order show the benefits of the methodology of the present invention, a series of components were injected molded utilizingpellets72 fabricated from low-density polyethylene (LDPE), high impact polystyrene (HIPS) and polypropylene (PP) in accordance with the methodology heretofore described, wherein nitrogen (N₂) was used as the first supercritical fluid. The pelletized polymeric materials were laden with three different levels of nitrogen (N₂), namely, 0% N₂; 0.21% N₂; and 0.27% N₂. Constant percentages of carbon dioxide, namely, 2.5% CO₂were introduced as the second supercritical fluids during the molding processes of the components. Referring toFIG. 2,

components

200,201 and202 molded frompellets72 formed from LDPE, HIPS and PP, respectively, without the addition of the supercritical nitrogen during the pellet fabrication processes, heretofore described, had large pore size and low cell density. However,

components

204,205 and206 molded frompellets72 formed from LDPE, HIPS and PP. respectively, and having 0.21% N₂by weight show a sharp reduction in cell size and an increase in the cell density. Similarly,

components

208,209 and210 molded frompellets72 formed from LDPE, HIPS and PP, respectively, and having 0.27% N₂by weight also showed a sharp reduction in cell size and an increase in the cell density. Hence, irrespective of the polymeric material used, it can be appreciated that the introduction of a first supercritical fluid during the pellet fabrication process coupled with the introduction of a second supercritical fluid during the injection molding process resulted in molded components having sharp reductions in cell size and increases in the cell density, as compared to the components wherein a single supercritical fluid was added to the polymeric material during the injection molding process.

Various modes of carrying out the invention are contemplated as being within the scope of the following claims particularly pointing and distinctly claiming the subject matter that is regarded as the invention.

Claims

We claim:

1. A method of fabricating an injection-molded component, comprising the steps of:

introducing pellets including a first supercritical fluid and polymeric material into an injection barrel of an injection molding machine;

plasticizing the pellets within the injection barrel;

introducing a second supercritical fluid into the plasticized pellets to form an injection material: and

injecting the injection material into a mold; wherein:

the first supercritical fluid and the second supercritical fluid are formed from different components; and

the first supercritical fluid is formed from nitrogen and the second supercritical fluid is formed from carbon dioxide.

2. The method ofclaim 1 comprising the additional steps of

providing a polymeric material;

heating the polymeric material and the first supercritical fluid to produce a melt;

extruding the melt; and

forming the pellets from the extruded melt.

3. The method ofclaim 2 wherein the extruded melt is unfoamed.

4. The method ofclaim 1 comprising the additional step of mixing the injection material prior to injecting the injection material into the mold.

5. The method ofclaim 1 wherein the injection molding machine includes a hopper communicating with the injection barrel and wherein the method includes the additional step of introducing the pellets into the hopper prior to introduction of the pellets into the injection barrel.

6. A method of fabricating an injection-molded component:

comprising the steps of:

providing a polymeric material;

introducing a first supercritical fluid into the polymeric material;

forming pellets from the polymeric material and the first supercritical fluid;

introducing the pellets into an injection barrel of an injection molding machine:,

plasticizing the pellets;

introducing a second supercritical fluid into the plasticized pellets to form an injection material; and

injecting the injection material into a mold; wherein:

7. The method ofclaim 6 wherein the step of forming pellets from the polymeric material and the first supercritical fluid includes the additional steps of:

heating the polymeric material id introducing first supercritical fluid to produce a melt;

extruding the melt; and

introducing the melt into a pelletizer.

8. The method ofclaim 7 wherein the extruded melt is unfoamed.

9. The method ofclaim 6 comprising the additional step of mixing the second supercritical fluid into the plasticized material prior to injecting the injection material into the mold.

10. The method ofclaim 6 wherein the injection molding machine includes a hopper communicating with the injection barrel and wherein the method includes the additional step of introducing the pellets into the hopper prior to introduction of the pellets into the injection barrel.

11. A method of fabricating an injection-molded component, comprising the steps of

introducing pellets into an injection barrel of an injection molding machine, the pellets including a first supercritical fluid;

plasticizing the pellets in the injection barrel;

mixing a second supercritical fluid and the plasticized pellets to form a mixed material; and

injecting the mixed material into a mold;

wherein the first supercritical fluid and the second supercritical fluid are formed from different components.

12. The method ofclaim 11 further comprising the additional step of forming pellets from a polymeric material and the first supercritical fluid.

13. The method ofclaim 12 wherein the step of forming pellets from the polymeric material and the first supercritical fluid includes the steps of:

heating the polymeric material and introducing the first supercritical fluid to produce a melt;

extruding the melt;

cooling the extruded melt into solid strands; and

introducing the strands into a pelletizer.

14. The method ofclaim 13 wherein the extruded melt is unfoamed.

15. The method ofclaim 11 wherein the first supercritical fluid is formed from nitrogen and the second supercritical fluid is carbon dioxide.

16. The method ofclaim 11 wherein the first supercritical fluid is formed from nitrogen.

17. The method ofclaim 11 wherein the second supercritical fluid is formed from carbon dioxide.

18. The method ofclaim 11 wherein the injection molding machine includes a hopper communicating with the injection barrel and wherein the method includes the additional step of introducing the pellets into the hopper prior to introduction of the pellets into the injection barrel.